Well, the bed is functional! I still have to trim out the side wall, order a custom foam cushion and a pair of wedge shaped bolsters.
I had another Aha! moment and realized I could re-use the upholstery from the skirt panels which hid the sofa frame. I checked it and found there was just enough extra material so that it would fit my panels. The end panels are thin OSB (5/16?), and the aisle panel is 1/2" OSB. I stapled cleats on the back of the thin panels before I upholstered them. The 1/2" panel, I just screwed into it from the back side. It seems strong. If the screws won't stay tight I will have to glue cleats onto that panel after the fact.
The result of this is a very factory looking job. Could I ever return it to factory stock? It would take some work and some new and different paneling. I probably will hang onto the sofa as long as we have the RV, just in case. It could be sold to someone who doesn't mind having the frame exposed underneath, such as for a toy hauler or cargo conversion etc.
I bought a 4" heating diffuser (vent) and a length of foil dryer vent tubing, which is the exact same stuff the factory used. I installed the new diffuser on the end behind the cab seat. I am not using the vent closest to the furnace. (There is not much use in having a heat supply vent about 3 feet from the cold air return.) My new setup should give a little better coverage. I don't know if this was needed or not, but it was easy and cheap enough to do.
Prior to this I just threw my photos quickly onto my Picasa account. At some point I will make an album for this project. When I do, the earlier photo posts of this project will probably lose their links. I guess if you want to make sure you have any of them, right click on them and save them to your PC.
In the last photo in this sequence, I stuck the dinette cushions on there just to give an idea of a finished look. That's NOT how we will be using it, I just did it for grins.








